Engine, Removing
Engine, removing.
Special tools and equipment
^ 2024 A Lifting tackle
^ T10012 Engine bracket
^ VW 313 Support clamp
^ VW 540 Engine and transmission support
^ V.A.G. 1202 A Workshop crane
^ V.A.G. 1306 Drip tray
^ V.A.G 1331 Torque wrench (5...50 Nm)
^ V.A.G 1332 Torque wrench (40...200 Nm)
^ V.A.G 1383 A Engine/transmission jack
^ VAS 5024 Assembly tool for spring-type clips
^ VW 540/1 B Supplementary set
^ VAS 5085 Step ladder
^ G 000 100 Grease (vehicles with manual transmission)
^ Bolt M10 X 25/8.8
^ Cable tie
Engine, removing
WARNING!
When performing repair work, especially due to the confined conditions in the engine well, pay attention to the following:
^ Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
^ Ensure sufficient clearance to all moving or hot components.
Note: During the further course of work the battery Ground strap must be disconnected Therefore, check first whether a coded radio is installed Obtain radio code first if necessary
^ Check Diagnostic Trouble Code (DTC) memories of all control modules before removing:
Refer to Diagnostic tester VAS 5051; Guided fault finding; Vehicle system test or VAS 5052; Vehicle self-diagnosis
Note:
^ Some components in this vehicle cannot be removed or are very difficult to remove when the engine is installed in the engine compartment. For this reason determine which components are faulty before starting to remove components and replace the faulty components once they have been removed.
^ The engine is removed downward together with the transmission.
^ All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing the engine.
^ With ignition switched off disconnect battery Ground strap.
^ Remove engine cover.
^ Drain coolant.
^ Remove battery and battery retainer.
^ Disconnect fuel supply line -1- as well as fuel return line -2- from fuel rail.
^ Disconnect hose from EVAP canister purge regulator valve -N80-.
WARNING! Fuel system is under pressure! Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.
^ Seal lines to avoid contamination of fuel system.
^ Observe rules for cleanliness, Refer to Powertrain Management, Fuel Delivery and Air Induction, Service and Repair, Rules for Cleanliness
^ Disconnect vacuum and breather hoses from engine.
^ Remove sound insulation tray.
^ Separate connections on following components:
Ignition coils with final output stages (-N70-1, -N127-, -N291-, -N292-
Camshaft Position (CMP) sensor-G40
lnjectors -N30-...-N33
Engine Coolant Temperature (ECT) sensor -G62
Engine speed (RPM) sensor-G28
Knock sensor 1 -G61
Knock sensor 2 -G66
Secondary Air Injection (AIR) pump motor -V101-
Oil pressure switch -F1-
Mass Air Flow (MAP) sensor -G70-
Throttle valve control module -J338-
^ Remove air cleaner with intake hose and Mass Air Flow (MAP) sensor -G70-.
^ Remove intake manifold upper part, Refer Intake Manifold, Service and Repair
Note: Seal the intake ports in the intake manifold lower section with clean cloths.
Models with manual transmission
^ Disconnect shift mechanism from transmission.
^ Remove hydraulic clutch slave cylinder:
Models with automatic transmission
^ Remove selector lever cable from transmission:
Continuation for all models
^ Remove ribbed belt.
^ Remove securing clamps for power steering pressure line.
^ Remove power steering pump with bracket and place to one side; hoses remain connected:
Models with air conditioning
^ Remove air conditioning compressor:
^ Additional information and removal work.
Continuation for all models
^ Disconnect inter-connecting coolant vacuum and intake lines on engine.
^ Unbolt secondary air injection pump and bracket and remove.
^ Disconnect all electric wires from transmission] alternator and starter and move clear.
^ Disconnect all other electrical connections as necessary from engine and place to one side.
^ Unbolt pendulum support (arrows).
^ Remove protective cover for right-hand inner constant velocity joint from engine.
^ Remove right-hand drive shaft and disconnect left-hand drive shaft at transmission:
^ Remove front exhaust pipe, Refer to Exhaust System, Service and Repair
^ Insert engine bracket T10012 in engine/transmission jack V.A.G 1383 A.
^ Secure engine bracket T1001 2 to front of cylinder block with securing bolt M10 x 25/8.8 to 40 Nm.
^ Tighten securing nut on exhaust side hand tight.
^ Lift engine and transmission lightly using engine/transmission jack V.A.G 1383A.
^ Unbolt engine side of assembly mounting from engine carrier at top (arrows).
Note: Use ladder VAS 5085 or equivalent to remove securing bolts.
^ Unbolt transmission side of assembly mounting from top of transmission carrier (arrows).
^ Carefully lower engine with transmission.
Note: Engine and transmission must be guided carefully when lowering to prevent damage to the bodywork, hoses and wiring.
Fastening engine to assembly stand
When working on the engine it should be secured to the assembly stand support clamp VW 313 using the engine and transmission bracket VW 540 and supplementary set VW 540/1B
Work sequence
^ Remove transmission.
Models with automatic transmission
^ Secure torque converter so that it will not fall out after separating engine from transmission.
Continuation for all models
^ Attach lifting tackle 2024 A as follows and lift off engine/transmission jack V.A.G 1383 A with workshop crane.
^ Pulley end: 3rd hole of lifting rail in position 2
^ Flywheel end: 3rd hole of lifting rail in position 8
WARNING! Hooks and locating pins must be secured with locking pins.
Note:
^ Positions marked 1 through 4 on the bar must face toward the belt pulley end.
^ The holes in the hook rails are counted up from the hook.
^ Secure engine to support clamp VW 313 using engine and transmission bracket VW 540 and supplementary set VW 540/1B. Dowel sleeves must be removed.